Motrona DS230 Series Safety Manual Download Page 1 | Manualshive

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Safety Manual

motrona GmbH, Zwischen den Wegen 32, DE - 78239 Rielasingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, [email protected], www.motrona.com

DS230 / DS240 series

Safety monitor for SinCos and incremental encoders / sensors

Product features:

•   Monitoring underspeed, overspeed, standstill and direction of rotation
•  SIL3 and PLe certification
•   Safety functions equivalent to EN61800-5-2 (SS1, SS2, SOS, SLS, SDI, SSM)
•   Mounting to 35 mm top hat rail (according to EN 60715)
•   USB interface for simple parametrization by the OS 6.0 operator surface
•   Optional available display and programming unit BG230 for parametrization and indication
•   Inputs for:

2 SinCos encoders

2 RS422 incremental encoders

2 HTL/PNP incremental encoders, proximity switches or control signals

• Outputs:

1 Relay Output 5 … 36 VDC (NO), (safety related)

1 Analog Output 4 … 20 mA, (safety related)

4 Control HTL Outputs, (safety related)

• Signal splitter:

1 SinCos Splitter Output, (safety related)

1 RS422 Splitter Output, (safety related)

Available devices:



DS230: All inputs and outputs as well as signal splitter function



DS236: All inputs and outputs, but without signal splitter function



DS240: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, with signal splitter function



DS246: 1 SinCos input (SIL3/PLe), 2 control inputs, all outputs, without signal splitter

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Summary of Contents for DS230 Series

Page 1: ...able display and programming unit BG230 for parametrization and indication Inputs for 2 SinCos encoders 2 RS422 incremental encoders 2 HTL PNP incremental encoders proximity switches or control signal...

Page 2: ...c sn ag 06 15 First edition series Rechtliche Hinweise All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH Any reproduction modification usage or publ...

Page 3: ...236 Block Diagram 10 4 4 DS236 Connections 10 4 5 DS240 Block Diagram 11 4 6 DS240 Connections 11 4 7 DS246 Block Diagram 12 4 8 DS246 Connections 12 5 Description of Connections 13 5 1 Power Supply 1...

Page 4: ...tional Mode 8 44 6 15 Operational Mode 9 45 7 Start Up the Unit 46 7 1 Setup by PC 47 7 2 Setup by the Programming Module BG230 48 7 3 Parameter Menu Overview 49 7 4 Parameter Description 51 8 Start U...

Page 5: ...he right to modify the hardware software or operation manual at any time and without prior notice Therefore there might be minor differences between the unit and the descriptions in operation manual T...

Page 6: ...cross sections for wiring are described in the technical specifications see chapter 11 Before first start up it must be ensured that all connections and wires are firmly seated and secured in the scr...

Page 7: ...at opportunity to save costs for expensive and certified sensors Also the costs for new installations and adjustments can be reduced significantly by using the existing components and wiring Typical e...

Page 8: ...N 60715 Inputs 3 2 Inputs for SinCos encoders 2 Inputs for incremental RS422 encoders 2 Inputs for HTL PNP incremental encoders or HTL PNP control signals 4 1 Input for SinCos encoder with SIL3 PLe 2...

Page 9: ...Ds230_03a_oi_e doc Jun 15 Page 9 100 4 Block Diagrams and Connections 4 1 DS230 Block Diagram 4 2 DS230 Connections...

Page 10: ...Ds230_03a_oi_e doc Jun 15 Page 10 100 4 3 DS236 Block Diagram 4 4 DS236 Connections...

Page 11: ...Ds230_03a_oi_e doc Jun 15 Page 11 100 4 5 DS240 Block Diagram 4 6 DS240 Connections...

Page 12: ...Ds230_03a_oi_e doc Jun 15 Page 12 100 4 7 DS246 Block Diagram 4 8 DS246 Connections...

Page 13: ...nCos Splitter Output X6 SINCOS IN 1 5 3 SinCos Inputs X7 SINCOS IN 2 5 3 SinCos Inputs X8 RS422 IN 1 5 4 RS422 Inputs X9 RS422 IN 2 5 4 RS422 Inputs X10 CONTROL IN 5 5 HTL Control Inputs X11 5 12 Inte...

Page 14: ...e range from 18 30 VDC Ripple 10 24 V External fuse 2 5 A medium time lag required A separate power pack must cover the following requirements The switch on current of the unit is maximum 2 5 A The co...

Page 15: ...2 Sensor2 X7 4 X7 5 X9 1 X9 2 X9 1 X9 2 Examples for the connection of encoders and the encoder supply can be found in chapter 6 When powering up the encoder supply the maximum input current of the s...

Page 16: ...pply voltage is approximate 2 V below the 18 30 VDC power supply at terminal X3 The maximum load of encoder supply is 200 mA each channel Sensor1 and Sensor2 Supply SinCos inputs RS422 inputs HTL inpu...

Page 17: ...ould rotate but the unit is incapable to detect speed or speed differences In order to detect this error the operator can use e g a control output of the unit which indicates standstill see Section 7...

Page 18: ...are switched via 1 relay An external encoder supply must be done in each case via a relay which is triggered by the auxiliary voltage of the unit The operator must ensure that the plant cannot reach a...

Page 19: ...always all existing signal lines SIN SIN COS and COS The internal SinCos encoder signal monitor verifies the Common Mode range of each signal line and is capable to detect cable fractures An evaluatio...

Page 20: ...RS422 format at the terminal strips X8 and X9 The RS422 input channels A and A resp B and B are internally terminated by a dynamic terminating circuit 220 pF 120 ohm It is mandatory to connect up all...

Page 21: ...X10 5 unconnected direction signal e g to evaluate a gear wheel by connecting a proximity switch The inputs X10 3 resp X10 5 may be unconnected internal pull down or can be used for a static direction...

Page 22: ...y a further target device The signal delay time between SinCos input and SinCos output is approximately 200 ns The channels SIN and SIN resp COS and COS must be terminated by 120 Ohm load resistors at...

Page 23: ...input signal SinCos resp HTL always incremental RS422 square wave pulses are generated at X4 RS422 OUT The signal delay time between the RS422 input and the RS422 output is approximately 600 ns In ca...

Page 24: ...utput is 0 mA The connection to the Analog Output is only safe if the following device is capable to detect the error state of the safety unit In case of errors the operator is responsible to ensure s...

Page 25: ...the output level is about 2 V below the supply voltage connected to terminal X3 24V IN Each output has a push pull output stage and short circuit protection When switching inductive loads additional e...

Page 26: ...conditions of the relay output are freely programmable by parameters see chapter 7 4 5 and 7 4 6 Further the opener is also integrated within all monitoring functions In case of an error the contact c...

Page 27: ...lf Test Message booting of the start up is faster 3 ON Normal Operation Parameter access disabled OFF Programming Mode allows access to the Parameters by display unit or PC Programming Mode DIL switch...

Page 28: ...erves for communication between the unit and an optional programming and display unit BG320 which can be plugged on the front 8 pin female connector X11 The programming and display unit BG230 and the...

Page 29: ...a PC or a super ordinate controller a serial interface simulation is accessible at the USB port For connection a standard USB cable with a Type B connector is used The USB cable is available as an opt...

Page 30: ...is running up self test in progress During normal operation error released by the process divergence of frequencies etc SLOW DIL1 OFF unit state Factory Settings DIL3 OFF unit state Programming Mode F...

Page 31: ...ailable 3 HTL encoder A B 90 X10 CONTROL IN HTL encoder A B 90 X10 CONTROL IN Not available Not available 4 HTL encoder A B 90 X10 CONTROL IN HTL encoder A at X10 CONTROL IN Not available Not availabl...

Page 32: ...s In Case of DS24x only operational mode 0 see chapter 8 4 1 Parameter 000 has to be used Mode Sensor1 Sensor2 Control1 Control2 0 SIL3 PLe SinCos encoder X6 SINCOS IN 1 Sensor1 and Sensor2 are intern...

Page 33: ...coder A at X10 CONTROL IN Speed Direction Standstill SIL3 PLe SIL3 PLe SIL3 PLe 3 HTL encoder A B 90 X10 CONTROL IN HTL encoder A B 90 X10 CONTROL IN Speed Direction Standstill SIL3 PLe SIL3 PLe SIL3...

Page 34: ...F HFT Type A B PFH PFD resp category DCavg and MTTFd and systematic safety integrity must be ensured for the entire protection circuit Software programs like SISTEMA are very helpful for creating such...

Page 35: ...This mode only DS23x is used to evaluate a dual channel system equipped with two SinCos sensors resp Encoders which must be performed in accordance to chapter 5 3 In this operational mode a DS230 var...

Page 36: ...plementary Achievable Safety Level Speed SIL3 PLe Direction SIL3 PLe Standstill SIL3 PLe This mode only DS24x is exclusively used to connect a SIL3 resp PLe certificated SinCos sensor encoder which mu...

Page 37: ...r a combination of a SinCos encoder and an incremental dual channel HTL encoder is used The SinCos encoder must be performed in accordance to chapter 5 3 and the incremental encoder to chapter 5 5 In...

Page 38: ...his mode only DS23x allows to evaluate a dual channel system equipped with two different encoder types Therefor a combination of a SinCos encoder and an incremental single channel HTL encoder is used...

Page 39: ...e This mode only DS23x allows to evaluate a dual channel system equipped with two incremental dual channel HTL encoders The encoder must be performed in accordance to chapter 5 5 A DS230 variant repro...

Page 40: ...be realized for example by using a self locking gearbox This mode only DS23x allows to evaluate a dual channel system equipped with two different encoder types Therefor a combination of an incremental...

Page 41: ...inear movement This can be realized for example by using a self locking gearbox This mode only DS23x allows to evaluate a dual channel system equipped with two identical encoder types Therefor a combi...

Page 42: ...el system equipped with two different encoder types Therefor a combination of a SinCos and a RS422 TTL encoder is used The SinCos encoder must be performed in accordance to chapter 5 3 and the RS422 T...

Page 43: ...vel Speed SIL3 PLe Direction SIL3 PLe Standstill SIL3 PLe This mode only DS23x allows to evaluate a dual channel system equipped with two identical RS422 TTL incremental encoders The encoder must be p...

Page 44: ...dual channel system equipped by two different incremental encoder resp sensor types Therefore an incremental RS422 TTL and a dual channel HTL encoder are used The RS422 TTL encoder must be performed i...

Page 45: ...This can be realized for example by using a self locking gearbox This mode only DS23x is used to evaluate a dual channel system equipped by two different incremental encoder resp sensor types Therefor...

Page 46: ...the DIL switch slider 3 to its OFF position unit state Programming Mode Connect the unit to the OS6 0 operator surface or alternatively to a BG230 programming and display unit Programming Mode DIL sw...

Page 47: ...is also available for download on www motrona com After a successful installation of the operator software OS6 0 and the USB driver see document installation USB driver the PC can be connected via a...

Page 48: ...done by the programming module BG230 The optional display and programming module BG230 is used for Parameter settings and diagnosis without a PC It is easily connectable by plugging onto the front of...

Page 49: ...029 Preselect OUT2 H 003 F1 F2 Selection 030 Preselect OUT2 L 004 Div Switch f 031 Preselect OUT3 H 005 Div Value 032 Preselect OUT3 L 006 Div f Value 033 Preselect OUT4 H 007 Div Calculation 034 Pre...

Page 50: ...me OUT2 Serial Menu 046 Pulse Time OUT3 068 Serial Unit No 047 Pulse Time OUT4 069 Serial Baud Rate 048 Pulse Time REL1 070 Serial Format 049 Hysteresis OUT1 071 Serial Page 050 Hysteresis OUT2 072 Se...

Page 51: ...setting must be 1 016 Position Drift1 Position Drift1 and Position Drift2 must be equal 017 Phase Err Count1 Phase Err Count1 and Phase Err Count2 must be equal 020 Direction2 Direction1 and Direction...

Page 52: ...X10 CONTROL IN available for control signals Not available 3 HTL encoder A B 90 X10 CONTROL IN HTL encoder A B 90 X10 CONTROL IN Not available Not available 4 HTL encoder A B 90 X10 CONTROL IN HTL enc...

Page 53: ...e unit The setting is valid for both inputs channels 0 001 9 999 sec 0 001 002 Wait Time Defines the period time of the lowest frequency resp the waiting time between 2 rising edges which is detected...

Page 54: ...rameter 000 is monitored and processed as basic frequency The basic frequency selection affects the following outputs Analog Output Control Outputs Relay Outputs And thus the following menus preselect...

Page 55: ...05 Div Value maximum Divergence Defines the maximum allowed percentage divergence between the frequencies of sensor1 and sensor2 If this value is exceeded the unit switches to an error status see para...

Page 56: ...nit reacts immediately to each frequency deviation 10 Medium filter The unit tolerates temporary deviations and fluctuations e g caused from torsion or mechanical vibrations and reacts delayed to devi...

Page 57: ...rror status 1 Normal state Before exiting the Programming Mode the Parameter always must be set to 1 2 Error clearing All errors reported by the unit will be reset A direct changeover between 0 and 2...

Page 58: ...tputs Relay Outputs And thus the following menus preselected thresholds in the Preselect Menu see chapter 7 4 5 switching behaviors in the Switching Menu see chapter 7 4 6 analog output in the Analog...

Page 59: ...00 0 017 Phase Err Count1 faulty pulse counting limit Important notes for DS240 DS246 see chapter 7 4 1 The DS unit is able to detect incorrect pulse sequences as well as faulty phase positions The er...

Page 60: ...specified by the Operation Mode 0 1 0 020 Multiplier2 1 10 000 1 021 Divisor2 1 10 000 1 022 Position Drift2 0 100 000 0 023 Phase Err Count2 1 1 000 10 024 Set Frequency2 500 000 0 500 000 0 Hz 0 025...

Page 61: ...mit values for the set up mode and production mode A switchover between the switching points High and Low can only be released by an external command resp by using one of the both control inputs at te...

Page 62: ...6 50 000 032 Preselect OUT3 L Lower switching point of output OUT3 X2 5 6 60 000 033 Preselect OUT4 H Upper switching point of output OUT4 X2 7 8 70 000 034 Preselect OUT4 L Lower switching point of o...

Page 63: ...ameter 027 ff Additional features which can be assigned to the output S self locking function see parameter 057 Lock Output H switching hysteresis see parameter 049 ff Hysteresis A start up delay see...

Page 64: ...ection values S H A 6 f Preselection Output switches in event of leaving the frequency band Preselection Hysteresis Only used with positive preselection values S H A 7 f 0 Output switches if a positiv...

Page 65: ...ion Hysteresis Only used with positive preselection values S H A 7 f 0 Output switches if a positive frequency e g clockwise direction is detected The directional information will be deleted immediate...

Page 66: ...044 ff no self locking function Parameter 057 can be assigned to the respective output 049 Hysteresis OUT1 Percental hysteresis of the adjusted switching point see parameter 027 and 028 0 100 0 0 050...

Page 67: ...nds 7 start up delay 64 seconds 8 start up delay 128 seconds 9 automatically until the value has been exceeded for the first time see chapter 7 4 5 0 9 0 The defined delay time window is valid for all...

Page 68: ...ts 1 to 5 are used to assign the lock function to the respective outputs The highest valued bit 6 determines if a locked output can be released exclusively by an external input signal bit 6 0 see chap...

Page 69: ...o assign the desired switching conditions to the selected outputs The outputs are selectable by using a 5 bit binary code Output RELAY OUT4 OUT3 OUT2 OUT1 Bit 5 4 3 2 1 Binary 10000 01000 00100 00010...

Page 70: ...eration both tracks generally must have opposite conditions but in the test mode arbitrary output conditions can be simulated The output conditions are assignable by a 9 bit binary code 0 511 0 OUT RE...

Page 71: ...asons both control inputs are complementary The switching conditions active HIGH or active LOW can be defined by parameter 063 Basically always the complementary signal of the direct input must be app...

Page 72: ...RG 10 Freeze Frequency1 Freezes the actual encoder frequency of Sensor1 stat PRG 11 Freeze Frequency2 Freezes the actual encoder frequency of Sensor2 stat PRG 12 Freeze Frequency12 Freezes the encoder...

Page 73: ...moving from LOW to HIGH X10 3 3 dynamic function active when moving from HIGH to LOW X10 2 and simultaneously moving from LOW to HIGH X10 3 0 3 0 064 Input 2 Function assigns a control function to inp...

Page 74: ...d 5 19 200 Baud 6 38 400 Baud 7 56 000 Baud 8 57 200 Baud 9 76 800 Baud 10 115 200 Baud 0 10 0 070 Serial Format format of the serial data 0 9 0 0 7 data bits parity even 1 stop bit 1 7 data bits pari...

Page 75: ...or the transmission of the initialization values to the operator surface OS6 0 respectively to the BG230 programming and display unit 0 The initialization values will be transmitted with 9600 baud Aft...

Page 76: ...t frequency sensor1 or sensor2 is exported at terminal X4 RS422 OUT Which input is assigned to which channel sensor1 or sensor2 is set in the operating mode see chapter 7 4 2 parameter 000 0 Sensor1 A...

Page 77: ...the conversion range in Hz Defines the final frequency at which the analog output should set its final value of 20 mA 100 000 080 Analog Gain gain of the D A converter in With a setting of 100 the fr...

Page 78: ...The unit must be in a mechanically and technically perfect condition The unit must be snapped onto a 35 mm DIN rail according to EN 60715 by using the clip at the rear It must be ensured that the per...

Page 79: ...the device function and the error detection time No Parameter Notice 000 Operational Mode 001 Sampling Time 002 Wait Time 003 F1 F2 Selection 010 Power up Delay 016 Position Drift1 017 Phase Err Coun...

Page 80: ...be used only if the RS422 output is used The RS422 output essentially depends on the following parameters No Parameter Notice 000 Operational Mode 074 RS Selector 8 2 5 Analog Output Settings These pa...

Page 81: ...39 Switch Mode OUT1 044 Pulse Time OUT1 049 Hysteresis OUT1 054 Startup Mode 055 Startup Output 057 Lock Output 062 Input1 Function 063 Input1 Configuration 064 Input2 Function 065 Input2 Configuratio...

Page 82: ...Startup Mode 055 Startup Output 057 Lock Output 062 Input1 Function 063 Input1 Configuration 064 Input2 Function 065 Input2 Configuration OUT4 No Parameter Notice 000 Operational Mode 003 F1 F2 Select...

Page 83: ...Preselect REL1 L 043 Switch Mode REL1 048 Pulse Time REL1 053 Hysteresis REL1 054 Startup Mode 055 Startup Output 057 Lock Output 062 Input1 Function 063 Input1 Configuration 064 Input2 Function 065 I...

Page 84: ...ively to an optional BG320 programming and display unit the operator surface OS6 0 must be installed correctly and running on the PC all Parameters must be set to correct values Commissioning may only...

Page 85: ...he switching characteristics and command assignments for the HTL inputs defined 2 Is the source input for the RS422 splitter output selected see parameter 074 3 Is the analog output scaled with a star...

Page 86: ...reduction between both encoders then the higher frequency must be adjusted to the lower one For this calculation the scaling factors see chapter 7 4 3 are used In the example above the frequency 2 is...

Page 87: ...Ds230_03a_oi_e doc Jun 15 Page 87 100 By scaling the frequency 1 both internally calculated frequencies are approximately equal and the calculated ratio is close to 0...

Page 88: ...It is imperative to test the function of the relay and the evaluation in the target device finally The user of the equipment is responsible for ensuring all relevant parts of the system to a safe sta...

Page 89: ...no more current range 4 20 mA is given All digital outputs are set to LOW no more inversion between Out X and Out X No more incremental signals are available at the RS422 output Tri State with pulldo...

Page 90: ...de H 0000 2000 H 0000 0020 GPI Error Error of the control inputs See runtime error error code H 0000 2000 H 0000 0040 CAP Error Internal error Switch off and switch on the unit If the error repeats co...

Page 91: ...0010 External Supply BG Error Error of the supply of the BG230 Remove the BG230 Switch off and switch on the unit If error code is off external error e g short circuit in the BG230 If error code is s...

Page 92: ...r Error of the phase of Sensor1 Check parameter 017 Switch off and switch on the unit H 0002 0000 Phase Channel 2 Error Error of the phase of Sensor2 Check parameter 024 Switch off and switch on the u...

Page 93: ...9 5 Error Detection Time Basically it is not possible to specify an exact error detection time because the error detection depends on many factors Reaction time The error detection time depends among...

Page 94: ...nt1 1 1000 10 4 0 B7 018 Set Frequency1 5000000 5000000 0 87 1 B8 019 Reserved 0 10000 1000 5 0 B9 020 Direction2 0 1 0 1 0 C0 021 Multiplier2 1 10000 1 5 0 C1 022 Divisor2 1 10000 1 5 0 C2 023 Positi...

Page 95: ...1000 0 4 1 F2 053 Hysteresis REL1 0 1000 0 4 1 F3 054 Startup Mode 0 10 0 1 0 F4 055 Startup Output 0 31 0 2 0 F5 056 Standstill Time 0 9999 0 4 3 F6 057 Lock Output 0 31 0 2 0 F7 058 Action Output 0...

Page 96: ...Parameter Min Value Max Value Default Characters Decimal Places Serial Code 078 Analog Start 5000000 5000000 0 87 1 H5 079 Analog End 5000000 5000000 100000 87 1 H6 080 Analog Gain 1 1000 100 4 0 H7...

Page 97: ...HTL encoders proximity switches or control commands HTL PNP 10 30 V max 15 mA max 1 kHz max 250 kHz X10 screw terminal 5 pin 1 5 mm SinCos output safety related Splitter output Signal tracks Amplitude...

Page 98: ...characteristic data Classification Approved Safety Function System structure System architecture DCavg SFF MTTFD PFH SD SU DD DU Safety functions SIL3 PLe depends on the used encoder input signals Cer...

Page 99: ...Ds230_03a_oi_e doc Jun 15 Page 99 100 11 1 Dimensions inclusive BG230 at front Front Rear DS230 BG230 option...

Page 100: ...Ds230_03a_oi_e doc Jun 15 Page 100 100 12 Certificate...

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